Frame for battery modules and method of installing battery packs

Abstract

A frame 1 for receiving battery modules and to be installed within a vehicle, comprises a front member 2, a rear member 4, a left side member 5 and a right side member 3. The frame also comprises at l

Description

TECHNICAL FIELD The present disclosure relates to a frame for a battery module and a method of installing battery packs in a vehicle. Aspects of the invention relate to a battery module frame, to an assembly of a battery module frame and a vehicle body and to a method of installing a battery pack in a vehicle. BACKGROUND Vehicles which run on electricity are known. It is known to provide a battery frame for receipt of battery modules. The battery frame and retained modules may be called a battery pack which provides the motive force to the vehicle. The power demand for a vehicle necessitates that many battery cells are used in battery modules and, typically, many modules are used in a pack. Accordingly, to install a battery pack it is necessary to bring the battery pack and the vehicle body into proximity, typically by lifting the battery pack towards the underside of the vehicle body and securing it in place. Due to the weight of the battery pack, any misalignment of the battery pack and the vehicle body as they are being brought into proximity is difficult to accommodate, this may be especially the case where universal lifting devices are used, for example lifting devices which are not specifically engineered to lift battery packs and are usable to lift other components in a vehicle production line. It is an aim of the present invention to address one or more of the disadvantages associated with the prior art. SUMMARY OF THE INVENTION Aspects and embodiments of the invention provide a frame for receiving battery modules, an assembly comprising a battery module frame and a vehicle body, and a method of installing a battery pack in a vehicle as claimed in the appended claims. According to an aspect of the present invention there is provided a corner casting for interconnecting a side member and an end member of a battery module frame, the corner casting comprising a surface for presentation to a corresponding portion of a vehicle and an indexing pin upstanding from the surface. The corner casting may comprise one or more apertures for receipt of fasteners to allow the casting to be secured to a vehicle body. According to anotheraspect of the present invention there is provided a frame for receiving one or more battery modules to be installed within a vehicle, the frame having a front member, a rear member, a left side member and a right side member and at least one casting defining a corner portion located between one of the side members and one of either the front member or the rear member, the casting comprising a surface for presentation to a corresponding portion of the vehicle and an indexing pin upstanding from the surface. Advantageously the provision of a casting having an indexing pm ensures alignment of the frame with the vehicle body during installation. In order to secure the frame to a vehicle body the frame may be located on a lifting device, such as a lifting platen. By providing an indexing pin the frame and the vehicle body can be brought into alignment as the two are brought into proximity and the indexing pin extends into a corresponding aperture. Once aligned the frame can be secured to the vehicle body. Optionally, the indexing pin is integrally formed with the casting. Conveniently, this means that the part can be formed in a single casting process and ensures the integrity of the indexing pin. The indexing pin may have a shaft which extends outwardly from the surface. The length of the indexing pin may be from 25 to 40 mm, for example from 27 to 37 mm, say for example 32 mm. Advantageously the length of the pin provides a suitable balance between earliest engagement of the casting (and hence the frame) and the vehicle body whilst not unduly adding to the weight of the casting and / or providing a projection which can foul on other parts of the vehicle. The indexing pin may have a chamfered leading end portion. The chamfered leading end portion may describe an included angle (that is an angle described by diametrically opposed portions of the chamfered leading end portion) which is between 30 and 60°, say between 40 and 50 °, for example 44 or 45°. The chamfered leading end portion may taper inwardly from a proximal end to a leading or distal end. The length of the chamfered portion may be from 4 to 12mm, for example from 5 to 10 mm. Advantageously, the chamfered leading end portion ensures that misalignment between the frame and the vehicle body can be accommodated. For example, because of the weight of the frame and included battery modules perfect alignment with the vehicle body may not be possible. By providing the indexing pin with a chamfered end portion the frame and the vehicle body can be brought into alignment as the two are brought into proximity by shifting one with respect to another as the chamfered is brought into closer proximity with a corresponding aperture. Once aligned the frame can be secured to the vehicle body. The indexing pin may comprise a conical outer periphery. The conical outer periphery may extend from a proximal end adjacent the surface to a distal or free end. However, such an arrangement may require more material to achieve a desired degree of taper and / or strength. Accordingly, the indexing pin may comprise an outer periphery provided by a cylindrical shaft and a chamfered leading end portion. The shaft may extend from the surface, the chamfered end portion may extend from the end of the shaft to a distal or free end of the indexing pin. Advantageously, this provides a balance between the required amount of taper (to accommodate the likely maximum amount of misalignment in use) and the amount of material used (which is important for lightweighting purposes). The indexing pin may have a substantially circular outer periphery. For example, the indexing pin may be elongate, thereby defining an elongate axis. The outer periphery of the indexing pin viewed in a direction orthogonal to the elongate axis may describe a substantially circular form. Advantageously, a circular, or at least substantially circular, form allows the indexing pin to accommodate misalignment equally in all directions. The indexing pin may be of annular form in cross section. For example the indexing pin may be in the form of an elongate annulus extending from a base to the distal or free end of the indexing pin providing a rebate. Advantageously, providing the indexing pin in the form of an annulus provides lightweighting advantages, for example over a solid indexing pin. Further, in the circumstances where the indexing pin is formed integrally with the casting, an indexing pin of annular form is easier to form. The indexing pin may comprise a continuous wall between the outer periphery and an internal periphery. The thickness of the wall adjacent the surface may be from 5 to 15 mm, for example from 7 to 12 mm, say 10 mm. By providing a wall of suitable thickness, the strength of the indexing pin is sufficient to transfer forces to the frame in the case of misalignment, for example in the circumstances where the frame has to shift relative to the vehicle body when the two are brought into proximity. The internal periphery may have a transverse dimension (e.g. diameter), in cross section, of from 6 to 15 mm, for example 7 to 12, say from 7 to 10 mm. The internal periphery may be of cylindrical form. However, the internal periphery may also be of conical, or frusto-conical, form. In particular, the internal periphery of the indexing pin may describe an inverted frusto-conical form such that the transverse dimension (e.g. diameter) at the base of the rebate is smaller than a transverse dimension (e.g. diameter) at the distal or free end of the indexing pin. It is understood that the inverted conical shape is beneficial as it allows for greater forces to be accommodated in use. The surface of the casting may define a first plane. The base of the rebate may define a second plane. The first plane and the second plane may be parallel to one another. The first plane and the second plane may be non-coterminous, such that the plane of the base and the plane of the surface are distanced from one another. For example, if the plane of the surface is horizontal the plane of the base will be above or below the plane of the surface, above being a desirable location. It is understood that the non-alignment of the base of the rebate with the surface allows the pin to accommodate greater forces in use, not least because of the greater amount of material ofthe casting pin at the juncture with the surface. The junction between the surface and the base ofthe indexing pin may be provided with a thickened region, for example a thickened region extending about the entirety ofthe indexing pin, for example in the form of an upstanding boss. Such a boss will further strengthen the indexing pin to allow it to accommodate forces, in use. The outer periphery of the shaft may have a transverse dimension (e.g. diameter), in cross section of 15 to 25 mm, say 18 to 22 m, for example 19 or 20mm. The maximum dimension of the outer periphery of the indexing pin may be manufactured to a high tolerance, say + / - 0.2 or 0.1 mm. The junction of the base of the rebate and the internal periphery of indexing pin may be radiused. The junction of the shaft and the boss may be radiused. The junction of the boss and the surface may be radiused. Providing radiused junctions may advantageously alleviate the build-up of stress, in use. The casting may be located between the front member and the right side member. Advantageously, using the front right casting allows for various datum positions to be provided in the same casting, thereby ensuring alignment of the various components of the vehicle. The frame may comprise a single ( / .e. one and one only) indexing pin. Perhaps surprisingly, the inventors have found that a frame comprising a single indexing pin is able to ensure alignment of the frame with a vehicle body. The use of a single indexing pin clearly has lightweighting advantages. There is further provided in another aspect of the invention an assembly of a vehicle battery frame as set out above and a vehicle body, the vehicle body having an aperture for receipt of the indexing pin. According to another aspect of the present invention there is further provided an assembly comprising a battery module frame and a vehicle body, the battery module frame having a corner casting comprising a surface for presentation to the vehicle body and an indexing pin upstanding from the surface, the vehicle body comprising an aperture for receipt of and receiving the indexing pin. Advantageously, the engagement of the indexing pin with the aperture ensures alignment of the battery module frame and the vehicle body to allow the two to be secured together. The vehicle body aperture may comprise a chamfered periphery. The vehicle body aperture may taper inwardly from an aperture leading edge. The vehicle body aperture may comprise a cylindrical portion. The cylindrical portion may be located at or towards a trailing edge. The vehicle body aperture may be from 2 to 4 mm long, say from 2.5 to 3.5 mm long, e.g. 2.7 to 2.9 mm long. Advantageously, the provision of the chamfer on the vehicle body aperture allows the accommodation of misalignment between the battery module frame and the vehicle body. For example, in the circumstances where both the indexing pin and the vehicle body aperture comprise chamfers even greater amounts of misalignment can be accommodated. The angle of the chamfer of the vehicle body aperture may describe an included angle (that is an angle described by diametrically opposed portions of the vehicle body aperture) which is between 30 and 60°, say between 40 and 50°, for example 44 or 45°. The angle of the chamfer of the vehicle body aperture may be substantially the same as that described by the chamfered leading end portion of the indexing pin. The vehicle body aperture may be substantially circular. Advantageously, a circular, or at least substantially circular, form allows the vehicle body aperture to accommodate misalignment equally in all directions. The vehicle body portion may comprise a boss surrounding the aperture. A boss or thickened region surrounding the aperture will strengthen the vehicle body and ensure that forces transferred thereto, for example in the even of a misalignment can be accommodate. The boss may be twice as thick as the surrounding portions. A boss thickness of from 4 to 8mm, say, 5 to 7 mm is particularly suited to be able to accommodate the forces in use. The vehicle body may comprise a further aperture for receipt of another pin. A component of the frame may have an aperture for receipt of said further pin. In an embodiment a side member or a rear member of the frame may comprise said aperture. Advantageously, the provision of a further aperture ensures alignment of the vehicle body and the battery module frame. For example the indexing pin may locate the battery module frame and the vehicle body relative to one other longitudinally and laterally, whilst the further aperture on the vehicle body and the aperture on the further casting may ensure location of the battery module frame and the vehicle body rotationally. A yet further aspect of the present invention provides a method of installing a battery pack in a vehicle, the method comprising: providing a battery module frame, the battery module frame comprising at least one corner casting comprising a surface for presentation to a corresponding portion of a vehicle body and an indexing pin upstanding from the surface; bringing the battery module frame into proximity with a vehicle body and allowing orcausing the indexing pin to engage with and protrude into a corresponding aperture on the vehicle body; and securing the battery module frame to the vehicle body. The method may comprise mounting the battery module on a lifting device such as a lifting platen, the lifting device comprising an upstanding pin for engaging with a portion of the vehicle body. Advantageously, the provision of an upstanding pin on the platen allows and ensures alignment between the battery module frame and the vehicle body. A further aspect of the invention provides a vehicle comprising a battery pack, the battery pack comprising the frame for battery modules set out above with one or more battery modules located therein. A still further aspect of the present invention provides a lifting device, the lifting device having a lifting surface sized to accommodate a battery pack for a fully electric vehicle comprising a battery module frame containing one or more battery cells, the lifting surface comprising a single (i.e. one and one only) upstanding pin sized and positioned to extend through an aperture provided in a battery module frame and into an aperture in a vehicle body, such that with the battery module frame located on the lifting surface the upstanding pin extends through an aperture in the battery module frame and, as the lifting device is raised, the upstanding pin engages an aperture in a vehicle body. The upstanding pin may be located at or towards the rear of the lifting surface, for example towards the rear right of the lifting surface. The battery module frame may comprise front, left, rear and right members defining a space for receipt of said one or more battery cells. The right member may comprise said aperture in the battery module frame. The aperture in the battery module frame may be in the form of an elongate slot. In this specification the terms left, right, front, rear correspond to the intended front, rear, left, right of the vehicle which is being constructed and / or relative to a datum position on a lifting device. In a vehicle production line there is a vehicle construction direction, that is the various components for a vehicle are brought together and the vehicle moves from station-to-station, for example, engine installed at a work station, wheels installed at a subsequent work station and so on. Where the battery pack is fitted to the vehicle or, more precisely, to the body in white, the battery pack (comprising a frame and battery modules) is lifted by a lifting device to bring the battery pack into proximity with the vehicle body to allow it to be secured in place. To ensure alignment between the battery pack and the vehicle body the lifting device, or a lifting surface of the lifting device, has a datum position with respect to which the battery pack is located. The datum position is typically at a position corresponding to the front (or at least intended front) of the vehicle. Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in anyway and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner. BRIEF DESCRIPTION OF THE DRAWINGS One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows a vehicle in accordance with embodiments of the invention; Figure 2 shows a frame for a battery module in accordance with embodiments of the invention; Figure 3A shows a perspective view of a component of the frame of Figure 2; Figure 3B shows a plan view of the component of Figure 3A; Figure 3C is enlarged view of part of Figure 3A; Figure 3D is a cross sectional view of a portion of Figure 3C; Figure 4A shows a perspective view from below of a portion of a vehicle body; Figure 4B is an enlarged view of a portion of Figure 4A; Figure 4C shows a plan view from above of the portion of Figure 4A; Figure 5 provides a representation of a method of installing a frame on a vehicle body in accordance with embodiments of the invention; Figure 6A provides a side elevation of a casting engaged with the vehicle body in accordance with embodiments of the invention; Figure 6B shows a plan view of the casting of Figure A; and Figure 7 provides a schematic representation of a lifting surface according to embodiments of the invention. DETAILED DESCRIPTION A vehicle 100 in accordance with an embodiment of the present invention is described herein with reference to the accompanying Figure 1. The vehicle 100 has installed therein a battery pack. As shown in Figure 2, the battery pack comprises a frame 1 for receiving battery modules. Typically the battery pack is installed under the floor pan of the vehicle 100. The battery pack is for providing at least a portion of the motive force to drive the vehicle 100. The frame 1 comprises a front member 2, a right member 3, a rear member 4, a left member 5 and a floor member 6 to define a substantially rectangular cuboidal receptacle 7 for receiving battery cells, for example battery cells provided in one or more battery modules (not shown). At each corner of the frame 1 there is a provided a casting 10a, 10b, 10c, 10d. The first casting 10a interconnects the front member 2 and the right member 3, the second casting 10b interconnects the right member 3 and the rear member 4, the third casting 10c interconnects the rear member 4 and the left member 5 and the fourth casting 10d interconnects the left member 5 and the front member 2. Each of the castings 10a-10d are formed as unitary bodies, cast from e.g. an aluminium alloy. Referring now to Figures 3a and 3b there are shown perspective and plan views of the first casting 10a. The first casting 10a has a main body part 11 extending from a first end 11 a, which in use is connected to the front member 2 in the frame 1, to a second end 11b which in use is connected to the right member 3 of the frame 1. The main body part 11 has a top 11 c and a bottom 11 d. Extending from the main body part 11, at a location between the top 11c and the bottom 11 d, and at substantial right angles to the main body part 11, is a connection part 12. The connection part 12 comprises a surface 13 which extends substantially parallel to the top 11c of the main body part 11. The connection part 12 has a first aperture 14a and a second aperture 14b provided 7 therethrough. A boss 14c extends about the first aperture 14a, whilst the second aperture 14b is surrounded by a raised portion 14d, which stands proud of the surface 13. Extending upwardly from the surface 13 is an indexing pin 15. The indexing pin 15 extends in substantial orthogonal relation to the surface 13 and is situated between the first aperture 14a and the second aperture 14b. As can be more clearly seen from Figure 3C, the indexing pin 15 has an outer periphery 15o comprising a circular cylindrical shaft 15a extending from the surface 13 and a chamfered leading end portion 15b, tapering inwardly from the end of the circular cylindrical shaft 15a to define a frusto-conical shape. That is, the chamfered leading end portion 15b tapers inwardly from the end of the shaft 15a to a distal or free end 15e of the indexing pin 15. About the base of the shaft 15a, at the proximal end 15c of the indexing pin 15, is a boss 15d. The outer periphery 15o of the indexing pin 15 has, in cross section, a circular form, whereas the indexing pin 15 has, in cross section, an annular form provided between the outer periphery 15o and an internal periphery 15i. As is best seen in Figure 3D, the internal periphery 15i of the indexing pin 15 defines a rebate 15r having a frusto-conical shape extending from a base or first end 15s of the rebate 15r to the distal end 15e of the indexing pin 15. The frusto-conical shape is inverted, such that the diameter D1 of the rebate 15r at the base or first end 15s is smaller than a diameter D2 at the distal end 15e. The junction of the base or first end 15s and the internal periphery 15i is radiused. Also, the terminal part of the internal periphery 15i is radiused at the distal end 15e. The base or first end 15s of the rebate 15r is not horizontally aligned with the uppermost surface of the boss 15d such that the rebate 15r is distanced from the uppermost or free surface of the boss 15d by a distance d. Although there is no intention to be limited by or bound to any particular theory, it is believed that individually and / or collectively, an internal frusto-conical shape of the rebate 15r, a radiused juncture of the base or first end 15s and the internal periphery 15i and / or a non-alignment of the base or first end 15s and the uppermost or free surface of the boss 15d provide the indexing pin 15 with the ability to withstand greater forces in use and / or allow for greater forces to be accommodated when being installed, as explained below. The first casting 10a, including the main body part 11, connection part 12 and indexing pin 15, is integrally formed as a one-piece casting in some examples. In a specific embodiment, the indexing pin 15 has a total length of 32 mm. The shaft 15a has an external diameter of 19 mm and an internal diameter D2 of just over 9mm (and a diameter immediately above the radiused juncture of the base 15s and the internal periphery 15i of about 8 mm) and the chamfered leading end portion 15b has a length of 7 mm. Consequently, the included angle defined by the chamfered end portion is 44°. Referring now to Figures 4A, 4B and 4C there are shown different views of a portion 20 of a vehicle body for the vehicle 100. The body portion 20 has a configuration comprising various shapes and apertures which are not material to the current invention. However, and in particular, the body portion 20 comprises an intended lowermost surface 21, extending through which is an aperture 22. As is best seen in Figure 4B, the aperture 22 comprises a chamfered periphery 22a tapering inwardly from the intended lowermost surface 21. As can be seen from Figure 4C, the body portion 20 comprises a boss 23 surrounding the aperture 22 and upstanding from an intended uppermost surface 24 of the body portion 20. In a specific embodiment the chamfered periphery 22a of the aperture 22 describes an included angle of 44° and has a diameter at or proximate the intended uppermost surface 24 of the body portion 20 of 20 mm. In order to provide a battery pack in a vehicle 100, the following steps may be taken, as indicated in Figure 5. • Ina step S1 a frame 1 is provided, the frame 1 retaining battery cells; • Ina step S2 the frame 1 is located on a lifting surface, typically in alignment with a nominal or actual datum position on the lifting surface; • Ina step S3, a vehicle body (or more typically the body in white) is located above the frame 1, typically in alignment with the nominal or actual datum position on the lifting surface; • In a step S4, the lifting surface is raised to cause the indexing pin 15 to engage with the aperture 22 of the body portion 20; and • In a step S5, once the frame 1 and body portion 20 are correctly aligned and in place the two are secured together by, inter alia engaging fasteners in the first aperture 14a and second aperture 14b of the casting 10. Figures 6A and 6B show the first casting 10a finally located with respect to the body portion 20 such that the indexing pin 15 extends through the aperture 22. Once the frame 1 is secured to the body in white, the rest of the components can be installed according to a production flow line to fabricate a vehicle 100. It will be appreciated that if the frame 1 and the body portion 20 are not perfectly aligned it will be difficult, if not impossible, to secure the frame 1 to the body portion 20, for example using (amongst others) fasteners which extend through the first aperture 14a and the second aperture 14b. However, the current invention addresses this problem. As the frame 1 is lifted into proximity with the vehicle body portion 20 the chamfered leading end portion 15b of the indexing pin 15 will be brought into approximate proximity with the chamfered periphery 22a of the 9 aperture 22 in the body portion 20. In case of any misalignment the respective chamfers of the chamfered leading end portion 15b of the indexing pin 15 and the chamfered periphery 22a of the aperture 22 in the body portion 20 will engage and thereby accommodate the misalignment by adjusting the position of the frame 1 on the lifting surface. Hence, in the case of misalignment, as the frame is lifted further the chamfered leading end portion 15b of the indexing pin 15 will engage the chamfered periphery 22a of the aperture 22 as they ride over one another it will cause a relative lateral component of force to be exerted. This lateral force will cause the frame 1 and the body portion 20 to be brought into alignment. As stated above, the frame 1 is usually aligned on the lifting surface with respect to a datum position, and the vehicle body is typically located above the frame 1 with reference to the datum position. Irrespective of how carefully the frame 1 (and / orthe vehicle body) is positioned, on a vehicle production line where many vehicles are being constructed a day, it is not feasible to align the frame (and / or the vehicle body) with respect to the datum position perfectly every time. Also, because this is the case, the frame 1 is not fixed on the lifting surface, even if it is positioned at least approximately with respect to the datum point on the lifting surface, whereby it can move on the lifting surface under the force exerted as the indexing pin 15 is inserted in the aperture 22. It will be appreciated that the frame 1, once it contains one or more battery modules and the associated electrical circuitry, is heavy (typically weighing more than 500kg). Surprisingly, an indexing pin 15 of the abovespecified dimensions, formed integrally with the comer casting 10a, is able to accommodate the forces exerted when attending to the aforementioned misalignment to move the frame on the lifting surface to bring the frame 1 and body portion 20 into alignment. As stated above, the indexing pin 15 is of circular form which allows the frame to accommodate mis-alignment through 360°. Surprisingly, a single indexing pin 15 provided on a single corner casting 10a-10d is sufficient to ensure alignment. It has also been found that it is beneficial to utilise the right front corner casting for this purpose because the front right casting also provides a datum point for attachment of the frame 1 to the vehicle 100. Also, because the indexing pin 15 is a component of the frame 1 it is possible to use a more universal lifting device, that is it is possible to use a lifting device which is not bespoke to lifting battery frames, such as frame 1 and can be used for other purposes in the vehicle production flow line. A suitable lifting surface is shown in Figure 7. Indeed, to further help with alignment of the frame 1 with respect to the vehicle body to which it is to be attached, a lifting device 50 such as that schematically represented in Figure 7 may be used. The lifting device 50 comprises a lifting surface 51 which can be moved vertically in the direction of arrow A. The lifting surface has a nominal or actual datum position 52 for alignment of an article such as the abovedescribed frame 1 thereon. The datum position 52 is located at or toward the front of the lifting surface 51 which, in a vehicle production line will correspond with the intended front of a vehicle to be fabricated. Extending from the lifting surface 51 is a single indexing pin 53. The frame 1, for example the rear right casting 10b of the frame 1, may be provided with a slot for receipt of the single indexing pin 53. When the frame 1 is located on the lifting surface 51, it will be located with respect to the datum position 52 and such that the single indexing pin extends through the slot. In accordance with the above teaching, the indexing pin 15 will cause the frame 1 and body portion 20 to become aligned. The single indexing pin 53 will enter into a corresponding aperture or slot in the vehicle body and will thereby ensure rotational alignment of the frame 1 and the vehicle body around the pin 15. By providing a lifting surface 51 with a single indexing pin 53, installation of the frame 1 on the lifting surface 51 is not unnecessarily complicated or delayed by having to align two spaced indexing pins with two spaced apertures in the frame. This helps to ensure that the vehicularthroughput ofthe process is not frustrated whilst also ensuring that the lifting surface 51 can be used for other tasks. As such, universality ofthe lifting device 50 is enhanced by providing an indexing pin 15 on the frame 1, rather than having two indexing pins on the lifting surface 51. Thus, in essence, the invention provides a positioning system for alignment, in a plane, of a battery frame with a vehicle body, wherein the vehicle body comprises two spaced indexing apertures for engagement in a lifting direction perpendicular to said plane by two indexing pins, one pin being disposed on a lifting surface, and the other being disposed on the battery frame, wherein the indexing pin on the lifting surface is engaged with an indexing aperture on the frame when the frame is located on the lifting surface and protrudes through the frame for engagement with one ofthe spaced indexing apertures on the vehicle body when the frame is lifted by the lifting surface in said lifting direction, and wherein the indexing pin on the frame and the other ofthe spaced indexing aperture on the vehicle body are mutually chamfered whereby, as they engage with one another when the lifting surface lifts the frame towards the vehicle body, misalignment ofthe frame on the lifting surface is corrected by displacement of the frame on the lifting surface about the indexing pin on the lifting surface when it is engaged with the body to align the frame with the body. This arrangement means that the frame has only to be: accurately positioned with respect to the lifting surface to engage the single indexing pin on the lifting surface with the corresponding indexing aperture on the frame, and approximately positioned on the lifting surface with respect to a datum point on the lifting surface spaced from the single index pin whereby, when the frame on the lifting surface is offered up to the vehicle body and the indexing pin on the lifting surface protrudes through the corresponding indexing aperture in the frame, the lifting device has only to be: accurately positioned with respect to the vehicle body to engage the single indexing pin on the lifting surface with the first indexing aperture on the vehicle, and approximately positioned with respect to the vehicle body to engage the indexing pin on the frame and the second ofthe spaced indexing apertures on the vehicle body. With the index pm on the frame and the corresponding indexing aperture on the vehicle body being mutually chamfered, and providing lateral displacement of the frame on the lifting surface is not inhibited, further lifting of the lifting surface with respect to the vehicle body causes the frame to slide on the lifting surface until the indexing pin and indexing aperture are precisely aligned and fully engaged. The frame is then against the vehicle body and fastening devices can be passed through mutually aligned apertures in the vehicle body and frame to fasten the frame to the vehicle body. Of course, it is also feasible that the indexing pin on the lifting surface and the corresponding indexing apertures on both the frame and on the vehicle may also be mutually chamfered to facilitate engagement, first of the lifting surface with the frame, when the lifting frame first engages the frame to lift it, and second of the indexing pin on the lifting surface with the indexing aperture on the vehicle body. It may be desired that the indexing pin on the lifting surface stands proud of the frame when the frame is on the lifting surface to a greater degree than indexing pin on the frame, whereby the indexing pin on the lifting surface is first engaged and aligned with its corresponding indexing aperture in the vehicle body before the indexing pin on the frame engages its indexing aperture in the body. It is to be noted that, if the indexing pin on the lifting surface and corresponding indexing aperture of the frame are mutually chamfered such that initial engagement of the lifting surface with the frame can be permitted to be only approximately correct when the lifting surface is first offered up to the frame, then relative lateral movement between the frame and lifting surface, in the plane perpendicular to the direction of insertion of the indexing pin, must not be inhibited. This may be achieved by the lifting surface comprising a lifting platen that is itself lifted by a device so as to have some freedom of adjustment on the device in said plane. Also, when the indexing pin on the lifting surface is precisely engaged with the corresponding indexing aperture on the vehicle, the only freedom of movement that is possible for the frame in the plane perpendicular to the lifting direction is in an arc centred on the indexing pin on the lifting surface. This requires the indexing pin to permit rotation of the frame about the indexing pin on the lifting surface, at least over the distance of mutual chamfering of the indexing pin on the frame and aperture in the vehicle body. This also permits the indexing pin on the frame, and corresponding indexing aperture in the vehicle body, not to be circular cylindrical in form but only to have mutual chamfering in the direction of said arc of possible movement. It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application.

Claims

1. A frame for receiving battery modules and to be installed within a vehicle, the frame having a front member, a rear member, a left side member and a right side member and at least one casting defining a corner portion located either between one of the side members and the front member or one of the side members and the rear member, the casting comprising a surface for presentation to a corresponding portion of the vehicle and an indexing pin upstanding from the surface.

2. A frame according to claim 1, wherein the indexing pin is integrally formed with the casting.

3. A frame according to claim 1 or 2, wherein the indexing pin comprises a shaft, a proximal portion of which is adjacent the surface.

4. A frame according to any of claims 1,2 or 3, wherein the indexing pin has a chamfered leading end portion.

5. A frame according to claim 4, wherein the chamfered leading end portion describes an enclosed angle of from 30 to 60° and / or has a length of from 4 to 12 mm.

6. A frame according to any preceding claim, wherein the indexing pin has a length of 25 to 40 mm.

7. A frame according to any preceding claim, wherein the indexing pin has an outer periphery of circular form8. A frame according to any preceding claim, wherein the indexing pin is of annular cross section, defining an internal periphery.

9. A frame according to claim 8, wherein the internal periphery describes a frusto-conical shape, optionally an inverted frusto-conical shape.

10. A frame according to any preceding claim, wherein the casting is located between the front member and the right side member.

11. An assembly comprising a battery module frame of any preceding claim and a vehicle body, the vehicle body comprising a vehicle body aperture for receipt of the indexing pin.

12. An assembly according to claim 11, wherein the vehicle body aperture comprises a chamfered periphery.

13. An assembly according to claim 11 or 12, wherein the vehicle body portion comprises a boss surrounding the aperture.

14. A method of installing a battery pack in a vehicle, the method comprising5 - providing a battery module frame, the battery module frame comprising at least one corner castingcomprising a surface for presentation to a corresponding portion of a vehicle body and an indexing pin upstanding from the surface;bringing the battery module frame into proximity with a vehicle body and allowing or causing the indexing pin to engage and protrude into a corresponding aperture on the vehicle body;10 - securing the battery module frame to the vehicle body.

15. A method according to claim 14, comprising mounting the battery module on a platen, the platen comprising an upstanding pin for engaging with a portion of the vehicle body.Application No: GB2412920.7Examiner:Catriona WhiteClaims searched: 1-15Date of search: 25 February 2025Patents Act 1977: Search Report under Section 17Documents considered to be relevant:Category Relevant to claims Identity of document and passage or figure of particular relevance X 1, 3, 7, 10, 11, 14 JP 2003146087 A (HONDA MOTOR CO LTD) see translation of document and figures 1- 3. Machine translation available at: Espacenet - Description <https: / / worldwide.espacenet.com / publicationDetails / description?CC=J P&NR=2003146087A&KC=A&FT=D&ND=3&date=20030521&DB= &locale=en_EP> [Accessed 25 / 2 / 25], A - US 2014 / 0246259 Al (YAMAMURA et al.) see paragraphs [0062]-[0066], [0101]-[0108], and figures 3, 19, and 24-29. A US 2015 / 0151624 Al (YAMADA et al.) see paragraphs [0033]-[0038], [0057]-[0058], [0063]-[0064], and figures 1-6. A CN 220465219 U (BEIJING SHENGNENG ENERGY TECH CO LTD) see translation of document and figure 1. Machine translation available at: Espacenet -Description <https: / / worldwide.espacenet.com / publicationDetails / description?CC=C N&NR=220465219U&KC=U&FT=D&ND=3&date=20240209&DB=& locale=en_EP> [Accessed 25 / 2 / 25],Categories:X Document indicating lack of novelty or inventive step A Document indicating technological background and / or state of the art. Y Document indicating lack of inventive step if combined with one or more other documents of same category. P Document published on or after the declared priority date but before the filing date of this invention. & Member of the same patent family E Patent document published on or after, but with priority date earlier than, the filing date of this application.Field of Search:International Classification:Subclass Subgroup Valid From B60K 0001 / 04 01 / 01 / 2019

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